INFO-ACSr

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1Rev. 0005

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Technical Data

AC Motor

Controller

100% Digital

Sampling rate- 12kHz (current, speed and position

control)

End stage- 2 types:

1.1 kW or 2.7kW rated power

Incremental input- RS422 signal- Electrically isolated

Resolver input- 12-Bit- 4096 Inc/U

Processor- PowerPC 403, 33/66MHz- 128kByte RAM- 128/512kByte Flash Eprom- Vector computer for current

transformation

2 outputs- 24V/500mA, electrically isolated

4 inputs- 3 inputs for use as required- 5V, electrically isolated

5V power supply- for incremental generator- 200mA max.

Highly precise and very fast positio-ning and control tasks are implemen-ted with the aid of the INFO-ACSrservo-controller. ACS servo-controllershave been systematically integrated inthe INFO-Link, i.e. there are no analoginterfaces or asynchronicities betweenthe field bus master and the controller.As with all intelligent periphery boards,a PowerPC processor ensures sufficient

power. Subordinated current, speedand position control is performed at a12KHz clock rate by the AC servo, withthe path curve, e.g. a trapezoid profile,being specified by the field bus master.Users have three different, simultane-ously active PID parameter sets at theirfree disposal. In addition, up to 6 pa-rameters can be recorded by means ofa logger.

Order No. INFO-ACSr 96231-6AOrder No. INFO-ACSr 96231-10AOrder No. INFO-ACSr 96231-30A

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Functions Description

AC servo-controllers have been systematically integrated in the INFO-Link. Thismeans that analog interfaces and asynchronicities between the field bus masterand the controller are a thing of the past. All parameters can be read and writtenvia the INFO-Link or via a serial connection using convenient tools (see controllermanual INFO-ACSr). The servo-controller no longer requires any potentiometersor other trimming instruments.PID parameters of trimmed axes can be loaded from a file to the non-volatile flashPROMs of the controller.

Users have three different PID parameter sets at their free disposal. The parametersets are simultaneously active, allowing optimal responses to load changes; forexample PID parameter set 1 for upward stroke with load; parameter set 2 fordownward stroke without load; parameter set 3 for stand-by with reduced powerconsumption. In addition to the PID parameters, it is possible to specify inputcontrols (boosters) for speed and acceleration.

The PowerPC 403-33MHz performs the following tasks at a 12kHz clock rate:

- PID position controller- Speed control- Active current control- Power-factor correction- Measuring wheel correction (resolver)- Limitation for: IMAX, I2t , controller temperature- Logger of 6 freely selectable parameters such as shaft speed, active current,

stroke error, target/actual speed, etc.

In addition to the resolver, an incremental encoder can be connected to thecontroller for measuring actual values and, depending on the application, can bedirectly integrated in the control algorithm or be used as an independent measuredquantity.

Different quantities of the AC servo controller are permanently monitored in orderto ensure maximum operational reliability. Short circuit cutouts prevent motor orground shorts. In the individual phases, fast overcurrent cutouts protect the endstage against destruction if the drive becomes jammed or is abruptly stopped.If the end stage is excessively heated, a warning signal is indicated at the controller.If the end stage is overheated, it is automatically switched off.

Three variants of the INFO-ACSr are available. The 6 and 10A versions differ bymatched measurement resistances: (phase currents)

INFO-ACSr -6A -10A -30A

PMOT 1.1kW 1.1kW 2.7kW

INENN 3ARMS 3ARMS 6ARMS

IMAX5S 6ARMS 10ARMS 20ARMS

UCC 325V 325V 325V

Variants

Operational reliability

Computing power

PID parameter sets

Measuring wheel

Integration inINFO-Link

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3Rev. 0005

Motion Control

Interfaces

RS232 Interface

Inputs

Outputs

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Connection

RS232 interfaceThe RS232 interface serves as a directconnection of the INFO-ACSr to the PC.

Encoder, inputsThe inputs are designed for 5V.If the inputs are operated with 24V, aseries resistor of 1.2kW is necessary.

The incremental encoder is connected tothe inputs 2, 3. Track A is connected toinput 2; Track B to input 3. The powersupply to the encoder is provided by theINFO-ACSr: 5V or 24V. Instead of anincremental encoder, it is also possibleto connect limit switches.Input 0 is reserved for external controllerenable. This input can be included in theEMERGENCY stop circuit.Input 1 is freely available to the program-mer.

OutputsThe two outputs are reserved for "motorcontrol active" and "current reductionactive".

ResolverThe actual position of the motor, measu-red by the resolver, is available at theoutputs A, B, and NM (connector1 32d... 32z) as an incremental encoder value.The signal is freely available to the user.A, B, NM are TTL signals. (74HC14; persignal two outputs in parallel)

Supply of incrementalencoderThe DC/DC converter on the board alsosupplies +5V to the encoder. This elimi-nates the need for a special power supplyfor the encoder (not electrically isolatedfrom the 24V supply).

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d b z

2 O + Active O - Active I + 24 V4 O + 24 V O 0 V I 0 V6 O + I-Red O - I-Red Shield8 O + 24 V O 0 V Shield

10 I + Ext. EN I - Ext. EN Shield12 O + 24 V O 0 V Shield14 I + In 1 I - In 1 Shield16 O + 24 V O 0 V Shield

18 I + INC A I - INC A Shield20 O + 24 V O 0 V Shield22 I + INC B I - INC B Shield24 O + 5 V O + 5 V Shield

26 I + Cos I - Cos Shield28 I + Sin I - Sin Shield30 O + Ref O - Ref Shield32 O + A O + B O + NM

d z

4 I + 325 V6 I + 325 V8 I + 325 V

10 O U12 O U

14 O V16 O V

18 O W20 O W

22 I - 325 V24 I - 325 V26 I - 325 V

28 I T.-Switch30 0 T.-Switch32 O Ground

Connector Allocations

Connector 1angledDIN 41612, Type F-482,8mm pins

Connector 2angledDIN 41612, Type H-156,3mm pins

Specifications

Power supply- Electrically isolated- Operating voltage: +18 ... 34V- Powe consumption: 380mA @ 24V

Climatic conditions- Ambient temperature:

Warehouse: -20...+80°COperation: 0 ... +45°C

- Board temperature:Operation: 0...+70 °C

- Relative air humidityNo condensation: 80%

Motor- Minimum inductance: 1mH- Minimum resistance: 0.9W- Max. motor voltage: 325V- Max. line length: 20m

Resolver inputs- Resolution: 4096 inc/r

(12-bit counter)- 4Vrms sine, bridge circuit- 2Vrms sin/cos input- Incremental shaft encoder output:

The resolver signal is additionallyprocessed as an incrementalsignal:Level: 5VA, B tracks, zero pulse

Intermediate circuit- INFO-ACSr operate with an

external 325V DC intermediatecircuit.(see INFO-AC1r, -AC3r)

End stage- IGBT end stage; 3 phases, 600V- Short-circuit protection:

Ground short, phase short- Temp. monitoring:

Precision: ± 2°- Dissipation power (IRATED)

INFO-ACSr-6A (IRATED=3A): 25WINFO-ACSr-10A (IRATED=3A): 25WINFO-ACSr-30A (IRATED=6A): 40W

INFO-ACSr

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5Rev. 0005

Motion Control

Y0 0

X

ErrorO

K

ControlIm

ax

Output

Active

Ucc

Power

Rec

PWM

ResolvM

otor

Inc AInput

Ext. E

n

Inc B

Com

Assembly Specifications

Sampling rate- Sampling rate: 12kHz

(current, speed and positioncontrol)

Outputs Out 0,1- Outputs electrically isolated:

VOFF: 48VION: 500mA

Inputs INP 0..3- Electrically isolated:- without connection: 5V- with 1.2kW series resistor: 24V

Incremental inputs- Incremental input with

A,B tracks- Interface: 5V / RS422- max. counting frequency: 2.5MHz

(12-bit counter)

5V supply- Voltage: 5V; +10%

max. current: 200mA- Supply for additional incremental

encoder (no electrical isolationfrom 24V board supply)

Installation- Connector DIN 41612,

Type F-48, Type H-15- Installation in 19" chassis- Dimensions: (LxWxH)

96231-6A: 105 x 234 x 25 mm96231-10A: 105 x 234 x 25 mm96231-30A: 105 x 234 x 35 mm

RS232 interface (violet)Communication with the controller iseither via the INFO-Link or via the RS232interface with the aid of the programACS-Show.

Addressing (blue)S1,S2 (Y0,0X) Axis Incremental encoder

(Adr.) (channel) (channel)

00 ... 03 0 ... 310 ... 13 4 ... 7

...70 ... 73 28 ... 31

80, 82 0, 2 1, 390, 92 4, 6 5, 7

...F0, F2 28, 30 29, 31

The incremental encoder can be directly integrated in the control algorithm. When0x80 is added to the current axis number (increase rotary switch Y0 by 8), theencoder will address the next channel number.In this connection, only even addresses are allowed for the controller so that theencoder will always come to lie on an odd address.

LEDs on receiver modulePower = +5V supplyRec = INFO-Link receiver signal OK

LEDsThe functions of the other LEDs on the front panel are described on page 7 and thefollowing pages.

Jumpers (light green)The jumpers influence the light intensity of the emitting LED and thereby thesegment length of the fiber cable up to the next board.

Segment length Jumper position 0 ... 10m no jumper 8 ... 30m >1020 ... 50m >30

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0J

Connection Example

Connection example

Connections

Board power supply

For the board power supply, a 3-phaserectifier without electrolytic capacitor issufficient. But to prevent interference, aelectrolytic capacitor of 4'700 ...10'000mF is recommended.The rack must be provided with a linefilter just after the entry of the powersupply.

Screened lines

The signals of the resolver are extremelysusceptible to interference; therefore, theresolver must be wired with a twistedpair, screened cable.

The incremental encoder and the serialinterfaces as well as the motor cablesmust always be connected through scree-ned lines!

Potential equalization

Always install all screens on both sides.To prevent undesirable leakage currentsvia the screening, it may be necessary toprovide a potential equalization line, es-pecially in case of long distances or dif-ferent power supplies.

Screening bar

A screening bar must be provided insidethe rack on which all screened cablesmust be placed.Metallic connectors with circumferentialcontacting of the screen are also suitablefor cable entries.

Plug-in connections

Interruptions in the resolver and motorcables at entries into cabinets etc. shouldbe made by metallic plug-in connectionsand not by clamp terminal connections.

Motor temperatur switch

open = Motor over temperaturclose = Ok

Inputs & outputs

The additional inputs and outputs:

External enable (Inp0) Free input (Inp1)Incremental encoder track A (Inp2) Incremental encoder track B (Inp3)Controller active (Out 0) Current reduction active (Out 1)

are only allowed to be wired inside the rack. If the cabling length exceeds 1m, theinputs and outputs must also be installed with screening.

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Grounding

Grounding ofINFO-ACSr

Connections

FilterThe 24V power supply must be providedwith a filter directly at the entry into therack.This is also true for the 230V of the powersection for the intermediate circuit.The optimal filter may have to be deter-mined by a measurement for line-boundemission, as the radiated interferencedepends, among other factors, on themotor cable length.

GroundingThe INFO-ACSr board is grounded at thefront panel. Take care to ensure that therack housing is connected in a conducti-ve way with the control cabinet. As theresolver is mounted directly on the mo-tor, it is essential to ground also thismotor-resolver combination, as other-wise the motor current will interfere withthe resolver electronics.

Screening plateIf the Stand Alone Master (INFO-SAM) isinstalled together with controllers of theINFO-ACSr series in the same rack, ascreening plate must be interposed bet-ween the master and the controller. Inaddition, the manufacturer recommendsa minimum clearance of 5 ... 10cm bet-ween the master and INFO boards car-rying high voltage. Possibly provideempty space.

See also Indel Wiring guidelines and Indeldesign guidelines.

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LEDs Function of LEDs on front panel

Inputs & outputs

Active Motor control active (Out 0)Requires external enable (Ext En, INP-0). End stage ON, motor energizedand 4k-Pos control on Active or Simulation.In the event of an error, the controller exits the active state.

Current reduction active mode (Out 1)In this mode, the controller limits the maximum current to Ired.Out-1 of 4k-Pos-Job = 1

External controller enable (INPUT 0)Interlocks the end stage by a hardware function, i.e. the controller cannot beactivated without external enable.INP-0 can be included in the emergency stop circuit. Without connection: 5V input,with 1.2kW series resistor connected: 24V input.

Free input (INPUT 1)Free 5V input, can be read in 4k-Pos job. (See software manual)

Encoder track A (INPUT 2)

Allocated as standard as encoder input A (additional measuring wheel).5V input, or RS 422 interface.

Encoder track B (INPUT 3)Allocated as standard as encoder input B (for additional measuring wheel).5V input, for RS 422 interface.

Emergency systemIn the emergency system, flash PROM burning is supported. In order to start thecontroller in the emergency system, a short-circuit termination must be connectedto the serial interface (front panel).

Connections: Signals PinRxD, TxD 2, 3DSR, DTR 6, 4

Once the controller has been started up, the short-circuit termination can beremoved and the serial cable to the PC can be reconnected.

Output

Ext. En

Input

Inc A

Inc B

OK Error

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9Rev. 0005

Motion Control

Flashing codeBy continuous lighting, fast or slow flashing, the LEDs indicate the statusof various controller funtions. The following applies for the sketches below:

E = ErrorW = Warning

Please use the program "ACS-Show" as an additional aid to verifyerrors. See also "Manual for AC-Servo Controllers".

Same rhythm as OK-LED on controller

approx. 3 times per second

approx. 1.5 times per second

Intermediate circuit voltage (325 VDC)(see also Modulation)

= E Intermediate circuit voltage lower than 20V

= E Intermediate circuit voltage higher than 385V

= W Intermediate circuit voltage lower than 260V

= Intermediate circuit voltage 261 ... 384V(optimal mode)

Motor current

= E I2t exceeded (I2t ³ 120%)

= E Motor overloaded or blocked(excessive load in case of excessive starting current).

= W I2t exceeded, motor current is limited to Irated

(I2t = 100 ... 119%)

= W IMAX reached; if the controller is operated in the current limitingmode, this warning will appear when Ired is reached.

Temperature end stage

= E End stage overheated (from (80°C)

= W End stage hot (from 75° C)= W End stage warm (from 60° C)

LEDsFunction of LEDs on front panel

Controller status

UCC

IMAX

Control

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LEDs Function of LEDs on front panel

Motor: temperature, short circuit

= E Motor short circuit, or end stage defective

= E Motor temperature switch activated more than 10s

= W Motor temperature switch activated

Resolver

= E Resolver connection defective or not correct.This error will also occur when the rotor is turning while the axis is switched active.

= E Maximum mechanical rotary speed exceeded

Modulation

= E Current offset too high (Test before Active)

= E Current measurement range exceeded

= W PWM 100% modulation reached (possibly UCC too low?)

If the motor is operated at high rpm, the PWM-LED starts to flash.UCC is fully modulated, i.e. the full intermediate circuit voltage is applied to themotor.This is an allowable operating condition.With high power (current) and high rpm, the intermediate circuit voltage will dropand the UCC-LED and the PWM-LED will start to flash. In this condition, thecontroller is not allowed to be in permanent operation.The loading limit is reached only when the controller exceeds the maximumallowable path error (increment, trailing error), and the controller switches to Error.

Important!

If the maximum rpm cannot be reached because path errors, trailing errors occurwhile the UCC-LED is flashing, the following causes must be checked:

- Inadequate power supply network (400V). Inadequately sized ortoo high-ohmic isolation transformer. Observe line length andcross-section of the supply line.

- Overloaded motor.

PWM

Resolver

Motor

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11Rev. 0005

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Remedy:

- Increase the intermediate circuit voltage by adding windings to the transformerObserve max. UCC=385V!

- In the presence of several controllers, split them up among different phases.- Possibly apply an additional power supply unit (INFO-ACPr).

CPU-OK, controller active

Controller deactive, OFF, CPU ok

Controller active, ON, CPU ok

Errors

= E Software error, CPU on Trap

Incorrect control parameters

= E After switching on the controller (not Active), theControl-LED together with the Error-LED show implausibleor missing Control parameters. With the factory-setparameters, this status display will appear.

Incorrect motor parameters

= E After switching on the controller (not Active), theMotor-LED together with the Error-LED show implausibleor missing Motor parameters. With the factory-setparameters, this status display will appear.

RAM error

= E When this error message appears, the controller mustbe subjected to a hardware revision. Please contact Indel AG.

Funktion der LEDs auf der Frontplatte LEDs

Error + Control

Error + Motor

Error + UCC

Error

OK

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Motion Control